Molded pulp tiles and structures

ABSTRACT

A simplified form of toy construction set, in which individual tile sections of molded pulp material are joined flexibly and reversibly. Molded tile elements are fabricated with a plurality of grooves, pockets and holes that act as receiving surfaces for assembly with elements that simulate roads and other features and permit the integration of other three-dimensional structural elements. The tile design permits representation of many different three-dimensional environments at different effective scales, with the ability to readily switch between these environments as desired during play.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/088,988, filed Dec. 8, 2014.

BACKGROUND OF THE INVENTION

1. Field of the Invention.

The present invention relates to a toy system fabricated using moldedpulp tiles and structures.

2. Background

The present invention relates to a toy system for young children.Various play sets that include tracks along which unpowered toy vehiclescan be moved are known. Such play sets have long been a source ofentertainment for children. Many of these sets focus only providingroadways or raceways for cars, or require construction skills thatrender them unsuitable for smaller children.

There is a need for construction toys that extend play beyondconventional tracks and roadways.. Further, there is a need for a uniqueand different construction set that can easily represent a variety ofimaginative play scenarios and that encourages the creativity of thechild by showing simple modes by which it may be extended and modified.At the same time, it should be suitable for very small children. Inparticular, it would be desirable to simulate many differentthree-dimensional environments at different apparent scales such as acity or town, village, farm, park, fort or zoo and to be able to readilyswitch between these environments as desired. Such toys should permitmany different configurations in three dimensions, thereby enhancing achild's enjoyment and play experience. For example, US 20140017975 A1teaches the construction of a known environment using a computer systemto incorporate images in printed parts. Conventional, injection-moldedplastic parts such as Lego™ or similar construction kits may be alsoused for such purposes. However, since each play element must beconstructed individually, modeling and constructing differentenvironments is a complex, time consuming and expensive task. At thesame time, plastic materials also have a significant environmentalburden and use of alternate, environmentally friendly or ‘green’materials is desirable.

Molded pulp products (MPP) can be manufactured by a number of processes.These processes permit design, rapid prototyping, and inexpensivemanufacture of complex, rigid three-dimensional (3D) structures thathave found primary applications in carton design and packaging (US2515113 A, US20140027337 A1, US 20110278187). They can be readilymanufactured in a variety of 3D form factors, in almost any desiredcolor, and with rounded, smooth surfaces that do not yield sharp edgesupon fracture. A further desirable aspect is that MPP are less densethan similar products made from wood and plastic and are thereforesignificantly safer for use by small children. MPP also conform topackaging crushability and other structural tests. MPP are alsoconsidered environmentally sustainable (ISO 14000 compliant) since theycan be readily manufactured from recycled materials and further recycledafter use.

These properties together suggest that molded pulp products can addressmany limitations in safety, costs and environmental impact of existingplastic (including High density polyethylene) molded parts in manyapplications for toy design.

SUMMARY OF THE INVENTION

The present invention describes an improved, simplified and inexpensiveform of construction set, in which individual tile sections of moldedpulp material can be joined quickly and easily by small children. Thearrangement enables users to quickly assemble a variety of tileconfigurations, incorporating tab-and-pocket jigsaw pieces that simulateroads, sidewalks, lanes, footpaths or waterways, and simulatingthree-dimensional environments on many scales, such as aregion/city/town/park or farm) either from provided assembly directionsor on a design-it-yourself basis, to provide optimum flexibility indesign and assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric projection of a first exemplary embodiment of asingle tile element

FIG. 2 is a plan view of a first exemplary embodiment of a single tileelement

FIG. 3 is a plan view of one embodiment of the toy system showing fourtile elements assembled together using interlocking planar tab-andpocket connectors with a road and sidewalk design

FIG. 4 is a plan view of one embodiment of the toy system showing fourtile elements assembled together using interlocking planar tab-andpocket connectors with a road and sidewalk design

FIG. 5 is an isometric view of one embodiment of the toy system showingassembly of a 3D building structure and assembly into the tile element

FIG. 6 is a section view of the building structure assembled into thetile element receiving pocket

FIG. 7 is an isometric view of one possible layout of the toy systemwith four tile elements assembled together using interlocking planartab-and pocket connectors and showing integration of building elements

FIG. 8 is a plan view of one embodiment of the toy system showing twotile elements assembled together using a frame with interlocking planartab-and pocket connectors

FIG. 9 is a plan view of one embodiment of the toy system showing twotile elements assembled together using a frame with interlocking planartab-and pocket connectors

FIG. 10 is a plan view of one embodiment of the toy system showing twotile elements assembled together using interlocking planar mortise andtenon connectors

FIG. 11 is a section view of one embodiment of the toy system showingtwo tile elements assembled together using interlocking planar mortiseand tenon connectors

DETAILED DESCRIPTION OF THE INVENTION

The present invention describes an improved, simplified and inexpensiveform of construction set, in which individual tile sections of moldedpulp material can be arranged and joined quickly and easily by smallchildren according to their wish. Molded tile elements are fabricatedwith a plurality of grooves, pockets and holes that act as receivingsurfaces for assembly with tab-and-pocket jigsaw pieces that simulateroads, sidewalks or waterways and permit the integration of other threedimensional structural elements by the child. Using these materials, thetile design permits representation of many different three-dimensionalenvironments at different effective scales such as a city or town,village, construction site, farm, park or zoo, with the ability toreadily switch between these environments as desired. The arrangementenables users to quickly assemble a variety of tile configurations,simulating a three-dimensional environment either from provided assemblydirections or on a design-it-yourself basis, to provide optimumflexibility in design and assembly. The materials used and thesimplicity of the design are highly suitable for very small children.The three dimensional structure of the play surface also directlyencourages imaginative play scenarios by suggesting how environments canbe built and modified using readily available materials and recycledpackaging etc., which further stimulate the creativity of the child.

Referring to FIG. 1-2, in one embodiment, the toy system consists of oneor more molded tile elements 1, each with a substantially planar uppersurface and with molded features 3 that form a raised ridge that definesfunctional regions 2, 4, 6, 8 and 10. The upper surface of the tileelements forming the planar base layer comprises a plurality of moldedgrooves and pockets 5, 7, 9 and 11.

During play, tile elements are arranged together in patterns accordingto the desire of the user to form a base layer, as shown in the examplein FIG. 3. Furthermore the tiles may be rotated so that the relativearrangement of surface features can be altered as required. Anyarrangement of tile elements may then, if the user so desires, be joinedto form the play surface 12 using tab-and-pocket ‘jigsaw’ elements 13.Each jigsaw section is provided at each end with at least one wide, flattongue element and one tongue-receiving slot of similar shape anddimensions, configured for convenient push-together joining to secure apair of adjacent pieces together. In the embodiment shown in FIG. 3,jigsaw elements 13 are laid or push-fitted into receiving grooves moldedon the tile surfaces. Alternately, the jigsaw sections can be providedwith barbs at one or both side edges to secure adjacent sections to thebase tile with a close, accurately aligned fit that assures a flat,smooth surface. In FIG. 3, the tiles are arranged in a 2×2 squarematrix, but any regular arrangement of tiles is possible depending onthe number of tiles used, since this provides that the functionalregions 12 on adjacent tiles are aligned so as to permit them to be‘bridged’ by jigsaw elements 13.

As shown in FIG. 4, the jigsaw elements 13 are printed and fabricated tosimulate a road system 14. In different embodiments these to definefeatures such as ‘roads, sidewalks, lanes, railroads or waterways’ assuggested by the play environment to be modeled. Jigsaw elements may beprinted one or both surfaces, providing additional flexibility. In otherembodiments, the jigsaw elements may include single or multiple ‘lane’roads. In other embodiments, roads may also be molded or delineated bystickers, paint or other post-fabrication processes.

FIG. 4 shows one of many possible arrangements of molded tile elementsjoined by jigsaw pieces to define the play surface 14, and which shows anetwork of streets and sidewalks defined by the jigsaw elements, allfeatures together suggesting the form of a road system within a modeltown or city. The envisaged tiles elements can be any practical sizefrom 2-100 cm on a side and any regular or irregular polygonal shapethat permits manufacturing, packaging and assembly by the end user.Ideally, larger tiles will permit road and/or train layouts that canaccommodate standard sizes of toy vehicles (generally classified as 1:64scale (though they range from smaller than 1:100 to much larger than1:64) and measure about 2.5-3 inches, or 6.5-7.5 centimeters, in length.Tiles may be manufactured or modified after manufacturing in a varietyof colors to suggest different environments, including urban, freeway,rural or off-road type environments and a variety of climate zone types,such as deserts or mountains.

The tile elements forming the planar base layer include one or moremolded features such as grooves, pockets or slots (5,7, 9 and 11 in FIG.2) that act as receiving surfaces on each tile element. Receivingsurfaces permit placement and temporary fixation of other objects (thatrepresent houses or other buildings) on the tiles. In the embodimentdepicted in FIGS. 1 and 2, the tile element consists of four areas 4, 6,8 and 10 defined by the molded ridges 3. Referring to FIGS. 5 and 6, inone embodiment, 3D structures 17, representing buildings, areconstructed from planar elements 15, 16 using tabs and pockets. Eachplanar element is printed on one or more sides to depict the side ofbuilding or structure to be represented by the complete assembly 17. InFIG. 5 and FIG. 6, the completed structures such as 17 are inserted intocognate pockets such as 19 on surface 20. The inserted structure isfurther supported by planar support inserts 21. The planar supportinsert 21 may be push fitted into the receiving area bounded by moldedridges 22 as shown in FIG. 6. Cylindrical structures 18 and otherregular or irregular polygonal receiving pockets 33, 34 and 38corresponding 3D structures such also envisaged. The mold also permitsthe fabrication of pockets that will accept multiple shapes such as 34(in which square and round pockets are combined. As shown in FIGS. 5-7,combinations of 3D structures are used to complete the depiction of thedesired play environment 23. In FIG. 7, the environment depicts acityscape 23 with a plurality of regular polygonal 24, 25 andcylindrical 18 structures that represent buildings. Further planarinserts printed with appropriate designs representing parking lots orparks may be placed in other receiving areas 4, 6, 8 and 10 to completethe depiction of the play environment. It should be obvious thatchanging the environment to be depicted can be achieved by rearrangingbuilding assemblies, planar inserts and jigsaw pieces.

In the embodiment shown in FIG. 3, adjacent tile elements are not joinedbut are connected at their upper surfaces using tab and pocket ‘jigsaw’elements 13. In another embodiment, depicted in FIG. 8, they may bephysically joined using ‘jigsaw’ tabs and pockets, or molded mortise andtenon joints as in FIG. 9 and FIG. 10.

In the embodiment depicted in FIG. 8, tiles are temporarily joined usingan independent frame fabricated in card or paper board with ‘jigsaw’tabs and pockets. In FIG. 8, Frame 26 is placed over and forms a securefit with tile element 28. Similarly, Frame 27 is combined with with tileelement 29, permitting temporary joining of two or more tiles 30 topermit construction of the play surface 13.

In the embodiment depicted in FIG. 9, the base of the tile is fabricatedwith a continuous lip 31 and 32 extending from the base of the sidewalls. This lip may be fabricated with ‘jigsaw’ tabs and pockets topermit joining of two or more tiles to form a play surface 35.

In the embodiment depicted in FIG. 10 and FIG. 11, the base of the tileis fabricated with a discontinuous lip 36 and 37 at the base of the sidewalls. This lip may be fabricated with mortises and molded tenons 39 topermit joining of two or more tiles to form a play surface 40.

Jigsaw elements 13 are utilized with tiles connected using either of theconnecting methods shown in FIG. 3 to FIG. 11 to create the playsurface. As in FIG. 4, any regular arrangement of tiles is possibledepending on the number of tiles used, since this provides that thefunctional regions 12 on adjacent tiles are aligned so as to permit themto be ‘bridged’ by jigsaw elements 13.

It should be obvious that the embodiments depicted in the drawings anddescribed above are intended as non-limiting examples of the intendedsystem. In particular, the use of multiple receiving areas on the sametile permits the creation of larger 3D structures.. A further embodimentwould permit the creation of receiving areas such as 4, 6, 8 and 10 bythe juxtaposition of two or more tiles. Furthermore, the use of jigsawelements and planar inserts printed on both sides would yield twoalternate play environments by placing the desired surface uppermost onthe tile surface.

We also envisage other molded 3D features that would represent thenatural environment (such as hills, mountains, rivers, lakes and otherwater bodies), features where the natural and man-made environmentsintersect, such as quarries or construction sites, molded features (suchas depressions, raised areas, slots or posts) that permit integrationwith other toy systems, such as Lego™ or Duplo™ base plates orBrio™-type railroad tracks.

We claim:
 1. A modular construction toy system comprising a plurality oftile elements, made from molded pulp material, each said elementcomprising side walls, a top having an upper surface that extends fromthe side walls, the top surface of each said element comprising aplurality of planar receiving surfaces, and an open bottom; a pluralityof interlocking connecting elements forming a substantially planarsurface; and a plurality of elements that can be assembled to form threedimensional geometrical structures.
 2. The tile element of claim 1, inwhich the base of the side walls terminates in a continuous molded lip,wherein said lip extends between 0.01 mm and 100 mm from the base of theside walls.
 3. The tile element of claim 2 with a plurality of tabs andpocket to permit temporary joining of two or more tile elements.
 4. Thetile element of claim 2 with a plurality of mortises and molded tenonsto permit temporary joining of two or more tile elements.
 5. The tileelement of claim 1, in which the base of the side walls terminates in adiscontinuous molded lip, wherein said lip extends between 0.01 mm and100 mm from the base of each side walls.
 6. The tile element of claim 5in which the lip comprises a plurality of tabs and pocket to permittemporary joining of two or more tile elements.
 7. The tile element ofclaim 5 in which the lip comprises a plurality of mortises and moldedtenons to permit temporary joining of two or more tile elements.
 8. Thetile element of claim 1, in which the base of the side walls are joinedtemporarily by a separate frame comprising a plurality of tabs andpocket to permit temporary joining of two or more tile elements.